Multidisciplinary Senior Design

Project Readiness Package

Project Title: / AATech Universal Oil and Bag System
Project Number:
(assigned by MSD) / P16680
Primary Customer:
(provide name, phone number, and email) / Jim Kalinski – Sr. Engineering Tech
(315) 902-5238

David DeWispelaere - Engineering Team Leader
(315) 902-5249

Wanda Crowley - Purchasing
(315)-902-5305

Sponsor(s):
(provide name, phone number, email, and amount of support) / Advanced Atomization Technologies
A Parker Aerospace & GE Joint Venture
124 Columbia Street
Clyde, NY 14433 USA
Preferred Start Term: / Fall 2015
Faculty Champion:
(provide name and email) / Gary Werth – Adjunct Facility
(315) 651-0014

Other Support: / As applicable
Project Guide:
(assigned by MSD) / Gary Werth – Adjunct Facility
(315) 651-0014

David DeWispelaere and Gary Wort / 7/30/15
Prepared By / Date
Sarah Brownell / 7/30/15
Received By / Date

Project Information

* Overview:

AATech manufactures fuel injection nozzles for aircraft (figure 1). Before packaging, each nozzle undergoes a procedure where it is attached to a holder and pressurized oil is sprayed through it. This process helps prevent rust during long term storage. More than 300 nozzles are processed each day. The PRP from last year includes background on the existing process which is manual.

Figure 1: Example Fuel Injection Nozzle and Location Schematic

Last year’s MSD team P15680 (https://edge/edge/P15680/public/Home) developed an enclosed test fixture and process to make this test easier and safer for the operator and less wasteful of oil (figure 2). The customer loved the outcome and has asked for more features. For example, the design was hard wired for a specific pressure and duration of oil spray.

The goal of this year’s project is to design and fabricate a system for oil and bagging nozzle assemblies other than the CFM nozzle that the previous MSD project team (P15680) focused on. This new team is tasked with adapting the system to accommodate different size nozzles, add computer controls for oil pressure and spray duration, and, as a stretch goal, automatically bag the nozzle after draining. This new system should have easily interchangeable tooling to support a variety of nozzle assemblies while still meeting the needs of the 2015 project. Each part number has its own fixture and oil spray duration and pressure.

Figure 2: Last year’s Prototype

The desired operating procedure is as follows:

·  Operator changes over tooling for selected nozzle

·  Enters part number

·  Operator loads part into fixturing

·  System engages oil flush tooling

·  System turns on pump and flushes nozzle at the required pressure and time duration

·  At end cycle tooling retracts

·  part is ready to be removed

* Preliminary Customer Requirements (CR):

·  Similar footprint to 2015 Project

·  Mobile

·  Capable of fixturing the following parts: (List to be supplied by 8/21)

·  Safely contains oil spray in all directions

·  Solution must be safe and meet ergonomic requirements of previous CFM Oil & Bag Project

o  Minimize back bending and wrist twisting

o  Prevent oil mist from entering human environment

o  Control noise level (50db or less)

·  Programming of oil spray duration and pressure automated by part number

·  System cannot leak

·  Keep skill level or operator the same

·  Maintain or improve current system cycle times

·  For RIT, 110V power is encouraged, but the plant has 3 phase 480V available.

·  Quick and easy change over to different part numbers

·  Automate bleeding to prevent operator getting sprayed

·  Utilize existing programed pressure and duration set points for oil flow

·  Capture excess oil for recycling

·  Budget of $10,000

* Preliminary Engineering Requirements (ER):

·  Footprint to be 2’ x 4’. Height to be set for ergonomic ease of use.

·  System shall ensure doors are closed prior to being able to start cycle

·  Test tank and plumbing shall not leak

·  System shall be capable of fixturing the following parts: (List to be supplied by 8/21)

·  Cycle time for these part shall be: (Will be supplied by part number with list above)

·  System shall be PLC controlled so operator can select part number and that will determine pressure and cycle time. Scanning bar codes for this would be an option.

·  Desired noise level from the system should be 50db or less.

* Constraints:

·  Power shall be sized for all applications and may be 110Vor 480V.

·  The system shall be portable.

·  Acrylic chamber should be housed in a par-frame structure. AA Tech will assist with procurement of par-frame ( approx. 4 weeks lead time).

·  The test chamber will be designed by team and reviewed with AA Tech. Then AA Tech will assist with procurement (lead time is typically 2-3 weeks).

·  Should be useable by an entry level operator

·  Total budget shall be $10,000, excluding the cost of the acrylic test chamber and par-frame to be supplied by AA Tech.

·  Preservation oil used to flush parts will be supplied by AA Tech (Reference Specification MIL-PRF-6081)

·  Use of an Allen Bradly PLC to remain consistent with other PLCs within the facility.

* Project Deliverables:

Minimum requirements:

·  All design documents (e.g., concepts, analysis, detailed drawings/schematics, BOM, test results)

·  System that is near production ready after review and check by AA Tech(fixtures, tooling, programs)

·  Training on how system works (can be done during runoff)

·  Technical paper

Additional required deliverables:

·  poster

·  All teams finishing during the spring term are expected to participate in ImagineRIT

† Budget Information:

·  $10,000 materials

·  AA Tech will procure chamber and all par-frame material with guidance from team

* Intellectual Property:

All legal markings need to be honored.

Project Resources

† Required Resources (besides student staffing):

Faculty list individuals and their area of expertise (people who can provide specialized knowledge unique to your project, e.g., faculty you will need to consult for more than a basic technical question during office hours) / Initial/date
Gary Werth
Environment (e.g., a specific lab with specialized equipment/facilities, space for very large or oily/greasy projects, space for projects that generate airborne debris or hazardous gases, specific electrical requirements such as 3-phase power) / Initial/date
3-phase power and Preservation oil (Reference Specification MIL-PRF-6081)
Equipment (specific computing, test, measurement, or construction equipment that the team will need to borrow, e.g., CMM, SEM, ) / Initial/date
Sample nozzles
Materials (materials that will be consumed during the course of the project, e.g., test samples from customer, specialized raw material for construction, chemicals that must be purchased and stored) / Initial/date
Oil to be supplied when requested for test – flushing of nozzles, chamber (per RIT Team Design) and par-frame
Other / Initial/date
N/A

† Anticipated Staffing By Discipline:

Dept. / # Req. / Expected Activities
BME
CE
EE / 2 / Motion controls, system logic and operator interface
(or ME’s with strong controls background)
ISE / 1 / Cycle time, safety, ergonomics
ME / 3 / Fixture, tooling, machine interface requirements, process design
Other

* Skills Checklist:

Indicate the sills or knowledge that will be needed by students working on this project. Please use the following scale of importance:

1=must have

2=helpful, but not essential

3=either a very small part of the project, or relates to a “bonus” feature

blank = not applicable to this project

Mechanical Engineering

/ ME Core Knowledge / ME Elective Knowledge /
1 / 3D CAD / Finite element analysis
Matlab programming / Heat transfer
2 / Basic machining / Modeling of electromechanical & fluid systems
2D stress analysis / Fatigue and static failure criteria
2D static/dynamic analysis / Machine elements
Thermodynamics / Aerodynamics
3 / Fluid dynamics (CV) / Computational fluid dynamics
3 / LabView / Biomaterials
Statistics / Vibrations
Materials selection / IC Engines
2 / GD&T
1 / Linear Controls
Composites
Robotics
Other (specify)

Electrical Engineering

/ EE Core Knowledge / EE Elective Knowledge /
1 / Circuit Design (AC/DC converters, regulators, amplifies, analog filter design, FPGA logic design, sensor bias/support circuitry) / Digital filter design and implementation
Power systems: selection, analysis, power budget / 2 / Digital signal processing
2 / System analysis: frequency analysis (Fourier, Laplace), stability, PID controllers, modulation schemes, VCO’s & mixers, ADC selection / 2 / Microcontroller selection/application
1 / Circuit build, test, debug (scope, DMM, function generator / Wireless: communication protocol, component selection
Board layout / Antenna selection (simple design)
Matlab / Communication system front end design
PSpice / Algorithm design/simulation
3 / Programming: C, Assembly / Embedded software design/implementation
Electromagnetics: shielding, interference / Other (specify)

Industrial & Systems Engineering

/ ISE Core Knowledge / ISE Elective Knowledge /
Statistical analysis of data: regression / Design of Experiment
Materials science / Systems design – product/process design
Materials processing, machining lab / Data analysis, data mining
Facilities planning: layout, mat’l handling / Manufacturing engineering
1 / Production systems design: cycle time, throughput, assembly line design, manufacturing process design / DFx: manufacturing, assembly, environment, sustainability
1 / Ergonomics: interface of people and equipment (procedures, training, maintenance) / Rapid prototyping
Math modeling: OR (linear programming, simulation) / 3 / Safety engineering
2 / Project management / Other (specify)
Engineering economy: Return on Investment
Quality tools: SPC
Production control: scheduling
Shop floor IE: methods, time studies
Computer tools: Excel, Access, AutoCAD
3 / Programming (C++)
RIT – Kate Gleason College of Engineering
Multidisciplinary Senior Design / Project Readiness Package
Template Revised Jan 2015